Workpiece positioning system

ABSTRACT

Embodiments provide a log positioning system configured to transport a log through one or more chipper/profiler modules to produce a cant with four chipped/profiled sides. In some embodiments, a log processing system may include an infeed, a positioning feed module downstream of the infeed, and one or more chipper/profiler modules disposed proximal to the positioning feed module. The positioning feed module may include a sharp chain coupled to one or more pairs of vertical positioning rolls. The positioning feed module may be selectively skewed, slewed, and/or tilted to match the vertical and angular orientation of the infeed.

CROSS REFERENCE TO RELATED APPLICATION

The present application is a division of U.S. patent application Ser.No. 14/027,010 filed Sep. 13, 2013, which claims priority to U.S. PatentApp. No. 61/714,744 filed Oct. 17, 2012, titled “WORKPIECE POSITIONINGSYSTEM,” the entire disclosures of which are hereby incorporated byreference in their entireties.

TECHNICAL FIELD

Embodiments herein relate to the field of lumber processing, and, morespecifically, to system, methods, and apparatuses for positioningworkpieces such as logs and cants.

BACKGROUND

Chipper canters are used in some sawmills to process logs, or blocks,into flitches, cants and boards. A chipper canter transforms logs intocants by removing outer portions of wood from two or four sides of thelog. However, force applied against the log by the chip heads may causethe log to shift on the conveyor, which can result in inaccuratepositioning of the log and sub-optimal chipping/sawing. In addition, thecurvature of some logs can present challenges to accurate chipping andsawing.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will be readily understood by the following detaileddescription in conjunction with the accompanying drawings. Embodimentsare illustrated by way of example and not by way of limitation in thefigures of the accompanying drawings.

FIG. 1 illustrates a perspective view of a log processing system;

FIGS. 2a-2b illustrate side and top views, respectively, of the logprocessing system of FIG. 1;

FIG. 3 illustrates a positioning feed module and other components of thelog processing system of FIG. 1;

FIG. 4 illustrates a simplified plan view of a positioning feed module;

FIGS. 5a-5b illustrate front and rear elevational views, respectively,of the components shown in FIG. 4;

FIG. 6 illustrates a schematic plan view of a positioning feed modulecarriage; and

FIGS. 7 and 8 illustrate additional details of the log processing systemof FIG. 1, all in accordance with various embodiments.

DETAILED DESCRIPTION OF DISCLOSED EMBODIMENTS

In the following detailed description, reference is made to theaccompanying drawings which form a part hereof, and in which are shownby way of illustration embodiments that may be practiced. It is to beunderstood that other embodiments may be utilized and structural orlogical changes may be made without departing from the scope. Therefore,the following detailed description is not to be taken in a limitingsense, and the scope of embodiments is defined by the appended claimsand their equivalents.

Various operations may be described as multiple discrete operations inturn, in a manner that may be helpful in understanding embodiments;however, the order of description should not be construed to imply thatthese operations are order dependent.

The description may use perspective-based descriptions such as up/down,back/front, and top/bottom. Such descriptions are merely used tofacilitate the discussion and are not intended to restrict theapplication of disclosed embodiments.

The terms “coupled” and “connected,” along with their derivatives, maybe used. It should be understood that these terms are not intended assynonyms for each other. Rather, in particular embodiments, “connected”may be used to indicate that two or more elements are in direct physicalor electrical contact with each other. “Coupled” may mean that two ormore elements are in direct physical or electrical contact. However,“coupled” may also mean that two or more elements are not in directcontact with each other, but yet still cooperate or interact with eachother.

For the purposes of the description, a phrase in the form “A/B” or inthe form “A and/or B” means (A), (B), or (A and B). For the purposes ofthe description, a phrase in the form “at least one of A, B, and C”means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).For the purposes of the description, a phrase in the form “(A)B” means(B) or (AB) that is, A is an optional element.

The description may use the terms “embodiment” or “embodiments,” whichmay each refer to one or more of the same or different embodiments.Furthermore, the terms “comprising,” “including,” “having,” and thelike, as used with respect to embodiments, are synonymous.

In exemplary embodiments, a computing device may be endowed with one ormore components of the disclosed apparatuses and/or systems and may beemployed to perform one or more methods as disclosed herein.

Embodiments herein provide systems, apparatuses, and methods forpositioning a workpiece, such as a log/cant. Log processing systems asdescribed herein may have a shorter length than typical existing primarylog lines and/or provide improved workpiece positioning capabilities.

As described more fully below, a log positioning system may beconfigured to transport a log through one or more chipper/profilermodules to produce a cant with four chipped/profiled sides. In someembodiments, a log processing system may include an infeed, apositioning feed module downstream of the infeed, and one or morechipper/profiler modules disposed proximal to the positioning feedmodule. The positioning feed module may include a sharp chain coupled toone or more pairs of vertical positioning rolls. The positioning feedmodule may be selectively skewed, slewed, and/or tilted to match thevertical and angular orientation of the infeed.

The infeed may be configured to convey a log in a first directiongenerally parallel to a longitudinal axis of the log, and to positionand/or tilt the log. The positioning feed module may adjust or maintainthe optimized position of the log while feeding the log into a firstpair of chip heads. The first pair of chip heads may be configured tochip vertical flat faces on the sides of the log. As the leading end ofthe workpiece (now a cant) exits the first pair of chip heads, thebottom of the workpiece is engaged by the sharp chain of the positioningfeed module. The vertical rolls of the positioning feed module contactthe chipped vertical faces of the workpiece and continue to drive theworkpiece in the first direction toward a second pair of chip heads. Thesharp chain and vertical rolls of the positioning feed module may beselectively skewed, slewed, tilted, and/or vertically repositioned inconcert to position the workpiece for chipping by the second set of chipheads. The second set of chippers may chip flat faces on the top andbottom of the workpiece.

In some embodiments, an optimizing scanner system may be providedupstream of the positioning feed module (e.g., positioned along theinfeed). A log turner may be positioned along the infeed and/or thepositioning feed module upstream of the first pair of chip heads. As alog is conveyed along the infeed, the optimizing scanner system may scanthe log and determine an optimized rotational position and optimizedcutting solution. The log turner may be controlled, directly orindirectly, by the optimizing scanner system to rotate the log optimizedrotational position before the log is engaged by the sharp chain andprocessed by the first and second pairs of chip heads.

Optionally, one or more profiler and/or saw units may be provideddownstream of the second pair of chippers. In one embodiment of a logprocessing system, a first pair of profilers is positioned downstream ofthe second pair of chip heads. A first saw module, such as a horizontalarbor saw, is positioned downstream of the first pair of profilers. Thefirst pair of profilers may engage and profile the vertical sides of theworkpiece, and the first saw module may subsequently cut side boardsfrom the profiled workpiece. A second set of profilers may be provideddownstream of the first saw module. The second set of profilers mayprofile the top and/or bottom of the workpiece. A second saw module,such as a vertical arbor saw, may be provided downstream of the secondset of profilers. The second saw module may cut the workpiece into twoor more pieces (e.g., boards).

FIG. 1 illustrates a perspective view of a log processing system 100.FIGS. 2a-2b illustrate side and top views, respectively, of logprocessing system 100. Referring first to FIG. 1, log processing system100 may include one or more of an infeed 102, a positioning feed module110, a first profile/saw section 128, a second conveyor 140, and asecond profile/saw section 150.

Referring now to FIGS. 2a-b , infeed 102 may include any type ofconveyor known in the art for transporting logs, such as a flightedchain conveyor. In a particular embodiment, the conveyor is selectivelyoperable to skew, slew, tilt, and/or vertically reposition a workpiece,such as a log/cant (101 a, 101 b) on the conveyor. An optimizing scanner106 may be provided along infeed 102. Optimizing scanner 106 may includea computing system communicatively coupled to one or more sensorspositioned along the conveyor of infeed 102. Optionally, optimizingscanner 106 may further include one or more additional sensors arrangeddownstream of the conveyor and/or downstream of infeed 102. Optimizingscanner 106 may be configured to scan a workpiece and determine anoptimized rotational position for the workpiece. In addition, optimizingscanner 106 may be configured to determine an optimized cutting solutionand/or optimized cut pattern for the workpiece. In some embodiments, logprocessing line 100 may include two separate scanners, with the firstscanner configured to provide rotation correction and the second scannerconfigured to provide turn detection (e.g., measure the actual logrotation against what was predicted) and/or source quality inspection(e.g., measure the horizontal position of the log against what waspredicted).

A log turner 108 may be positioned proximal to infeed 102. In someembodiments, log turner 108 may be positioned between infeed 102 andpositioning feed module 110. Log turner 108 may include knuckle turnerrolls that will handle logs up to 18″ diameter. Alternatively, logturner 108 may be a reciprocating log turner configured to accommodatelogs of greater diameter (e.g., up to 30″). Log turner 108 may turn thelog to the optimized rotational position determined by optimizingscanner 106. Optionally, one or more of the sensors of optimizingscanner 106 may be positioned to monitor the position of the log before,after, and/or during the turn. For example, a first group of sensorspositioned along infeed 102 may be used to scan the log for calculationof optimized rotational position, and the first group of sensors and/ora second group of sensors positioned downstream of the first group ofsensors may be used to monitor the rotational position of the log.Optimizing scanner 106 may be configured to detect the actual rotationalposition of the log and to calculate a difference between the actualposition and the optimized rotational position and/or predictedrotational position. Based on the calculated difference, optimizingscanner 106 may generate one or more commands to cause log turner 108 tocorrect the rotational position of the log (e.g., to continue the turnor initiate an additional turn). Optimizing scanner 106 may also measurethe horizontal position of the log against a predicted horizontalposition and calculate a difference between the actual horizontalposition and the predicted horizontal position. Based on the calculateddifference(s), optimizing scanner 106 may generate one or more commandsto adjust positioning feed module 110 and/or a downstream cutting tool(e.g., chip heads and/or a saw) to offset the calculated difference(s).

Positioning feed module 110 may be disposed downstream of infeed 102and/or log turner 108. FIGS. 3 and 4 illustrate additional details ofpositioning feed module 110 and additional components of log processingline 100. As best shown in FIG. 3, positioning feed module 110 mayinclude a sharp chain 112 operatively coupled to one or more pairs ofvertical feed rolls 120 (vertical feed rolls 120 a, 120 b), 122(vertical feed rolls 122 a, 122 b), and 124 (vertical feed rolls 124 a,124 b). Once the log has been turned, log turner 108 may deposit the logonto sharp chain 112. Sharp chain 112 and vertical feed rolls 120, 122,and 124 may be selectively repositioned in unison to match the verticalorientation and angle of infeed 102.

A first pair of chip heads 118 a and 118 b may be arranged on oppositesides of sharp chain 112. Chip heads 118 a and 118 b may be side chipheads configured to chip vertical faces along the lateral sides of aworkpiece. A second pair of chip heads 130 a and 130 b may be positioneddownstream of chip heads 118 a/118 b (e.g., at or near the terminal endof positioning feed module 110). Chip heads 130 a and 130 b may be topand bottom chip heads, respectively, configured to chip horizontal facesalong the top and bottom of the workpiece. Chip heads 130 a and 130 bmay be vertically aligned, with chip head 130 a positioned above chiphead 130 b. Chip head 130 b may be a fixed-position chip head, and chiphead 130 a may be vertically repositionable relative to chip head 130 bto accommodate various workpiece sizes and cut patterns. Alternatively,chip head 130 a may be a fixed-position chip head and chip head 130 bmay be vertically repositionable. As still another alternative, chipheads 130 a and 130 b may both be vertically repositionable. In someembodiments, some or all of chip heads 118 a, 118 b, 130 a, and 130 bare conical chip heads configured to create a smooth surface finish onthe cant.

Sharp chain 112 may extend between the first pair of chip heads 118a/118 b. In some embodiments, sharp chain 112 may also extend betweenthe second pair of chip heads 130 a/130 b. Alternatively, chip heads 130a/130 b may be positioned downstream of sharp chain 112. Vertical feedrolls 120, 122, and 124 may move vertically/laterally with the chain tomaintain the vertical lift, slew and skew of the log as it enters thesecond pair of chip heads 130 a/130 b.

One or more overhead press roll assemblies 116 may be provided alongsome or all of the length of sharp chain 112 to help maintain theworkpiece in a desired position. Centering feed rolls 114 may bepositioned along sharp chain 112 upstream of the first pair of chipheads. Likewise, additional vertical feed rolls 132 may be positioneddownstream of the second pair of chip heads 130 a/130 b. In contrast tovertical feed rolls 120, 122, and 124, vertical feed rolls 132 may havefixed positions, such that they are not repositioned in unison withsharp chain 112.

As the workpiece travels into the first pair of chip heads 118 a/118 b,the workpiece may be maintained in position by overhead press rolls 116,sharp chain 112, and centering feed rolls 114. The first pair of chipheads 118 a/118 b may create vertical chipped faces that are engaged byvertical feed rolls 120, 122, and 124 to guide the workpiece into thesecond pair of chip heads 130 a/130 b. Sharp chain 112 and vertical feedrolls 120, 122, and 124 may be selectively repositioned to slew, skew,lift and/or tilt the workpiece to create the desired opening face withchip head 130 b. The workpiece may be stabilized by the downward forceexerted by the first pair of chip heads 118 a/118 b chipping down intothe workpiece. In addition, the upstream chip heads 118 a/118 b mayprovide lateral support to the workpiece to counteract the lateral forceexerted by the second pair of chip heads 130 a/130 b, resulting inimproved workpiece stability and positioning. Optionally, one or moreguides may be positioned upstream of the second pair of chip heads 130a/130 b to help guide the workpieces into the chip heads.

The positioning feed module 110 may include a carriage 160, illustratedin FIG. 6. Carriage 160 may include two sides, one on each side of sharpchain 112, and a rail guide system that facilitates in/out and up/downshift of the two sides relative to sharp chain 112 to set the desiredcant width. This may allow carriage 160 to be adjusted to accommodatedifferent cant widths. In some embodiments, carriage 160 may includeseparate carriages on each side of sharp chain 112. Carriage 160 maysupport the pairs of vertical feed rolls 120, 122, and 124, andactuators 126. Vertical feed rolls 122 may remain in a fixed positionwith respect to carriage 160. In contrast, vertical feed rolls 120 and124 may be selectively articulated/repositioned relative to carriage 160by actuators 126 (e.g., air/hydraulic cylinders, linear positioners,etc.). Optionally, missed face logic may be employed, such that anactuator 126 is extended only when no chipped face is present at thecorresponding vertical positioning roll (see e.g., FIG. 6, verticalpositioning roll 124 b extended by corresponding actuator 126 wherechipped face is absent). This may allow the opposite side of theworkpiece to be chipped with greater accuracy. Optionally, some or allof the vertical feed rolls 120, 122, and 124 may be equipped with rollscrapers to keep the knurl clean.

A centerline chain drive and chain support may be coupled to sharp chain112. In some embodiments, the chain drive may be manufactured frompolyester. A cylinder may be configured to lift the vertical feed rolls120, 122, and 124 and the outfeed end of sharp chain 112 to maintain thelift/slew/skew of the workpiece as it travels into the second pair ofchip heads 130 a/130 b. Knife edge support bars (e.g., support 113) maybe provided on each side of sharp chain 112 to support the workpiecebetween the downstream end of sharp chain 112 (e.g., at a head sprocketof the sharp chain) and chip head 130 b.

A first profile/saw section 128 may be positioned downstream of thesecond pair of chip heads 130 a/130 b. First profile/saw section 128 mayinclude a first pair of profiling heads 134 a and 134 b, vertical feedrolls 136, and a skid bar 152 (see FIGS. 4 and 7). Optionally, guides158 may also be provided proximal to the first pair of profiling heads(FIG. 7). Profiling heads 134 a and 134 b may be configured to profilethe vertical sides of the workpiece. In the illustrated example, each ofprofiling heads 134 a and 134 b are four-stepped profiling heads thatcreate eight separate side board notches on the sides of the workpiece(see e.g., FIG. 5b ). However, this example is not intended to belimiting, and profiling heads 134 a and 134 b may have any suitableconfiguration or number of steps. Profiling heads 134 a and 134 b mayslide up and down on vertical splined arbors. Profiling heads 134 a and134 b may be driven by drive motors (e.g., 200 hp drive motors). In someembodiments, the chain drive may be manufactured from polyester.Profiling heads 134 a and 134 b may be supported on a carriage thattilts to accommodate skewing the side boards.

After processing by the second pair of chip heads 130 a/130 b, theworkpiece may proceed along skid bar 152 (FIG. 4) to profiling heads 134a/134 b. Vertical feedrolls 132 positioned upstream of the profilingheads and additional vertical feedrolls positioned downstream of theprofiling heads may maintain the workpiece in position (see e.g., FIG.7). A first saw assembly 138 may be provided downstream of the profilingheads. First saw assembly 138 may include a band saw, an arbor saw, orany other suitable type of saw. For example, as illustrated, first sawassembly 138 may include one or more horizontal arbor saws 138 a, 138 bpositionable to saw one or more side boards from the workpiece.

In some embodiments, first saw assembly 138 may include a quad arborsawbox with a shifting saw carriage on each side and fitted with fixedbottom arbor and tilting top arbor. The top arbor may equalize the depthof cut. Optionally, the top arbor may be actuated with a hydraulic servovalve. First saw assembly 138 may further include a sawguide system with#3 splined sleeves (6″ diameter) and a profile rail guide system thatallows for in/out shift.

A second conveyor section 140 may be positioned downstream of first sawassembly 138. Second conveyor section 140 may include a conveyor 156 andone or more overhead positioning roll assemblies 142 positioned aboveconveyor 156. Conveyor 156 may be a sharp chain conveyor. As theworkpiece proceeds onto/along second conveyor 156, one or more sideboards cut by first saw assembly 138 may be separated or diverted byconventional means for further processing. In some embodiments, sidepinch rolls may contain the side boards, and may be actuated with ahydraulic linear positioner.

A second profile/saw section 150 may be positioned downstream of secondconveyor 156. As best shown in FIG. 8, second profile/saw section 150may include additional vertical positioning rolls 144, a second pair ofprofiling heads 146 a/146 b, and a second saw assembly 148. As theworkpiece proceeds from second conveyor 156 toward profiling heads 146a/146 b, vertical positioning rolls 144 may maintain the workpiece inposition for profiling. Profiling head 146 a may be positioned toprofile the top of the workpiece, and profiling head 146 b may bepositioned to profile the bottom of the workpiece. Additional verticalpositioning rolls 144 located downstream of profiling heads 146 a/146 bmay maintain the workpiece in a desired position as the workpiece exitsthe profiling heads and proceeds toward second saw assembly 148.

Second saw assembly 148 may include a straight-sawing gang.Alternatively, second saw assembly 148 may include a curve-sawing gang.In one embodiment, second saw assembly 148 may include a double verticalarbor gang saw. As the workpiece proceeds through second saw assembly148, the workpiece may be sawn into boards. Additional verticalpositioning rolls located downstream of second saw assembly 148 may helpto maintain the workpiece in a desired position for sawing.

Although certain embodiments have been illustrated and described herein,it will be appreciated by those of ordinary skill in the art that a widevariety of alternate and/or equivalent embodiments or implementationscalculated to achieve the same purposes may be substituted for theembodiments shown and described without departing from the scope. Thosewith skill in the art will readily appreciate that embodiments may beimplemented in a very wide variety of ways. This application is intendedto cover any adaptations or variations of the embodiments discussedherein. Therefore, it is manifestly intended that embodiments be limitedonly by the claims and the equivalents thereof.

1. (canceled)
 2. An apparatus for positioning a log, comprising: a sharpchain configured to convey the log in a direction of flow; a carriagecoupled with the sharp chain, the carriage having a first portion and asecond portion disposed on opposite sides of the sharp chain, one orboth of the portions being selectively repositionable toward and awayfrom the sharp chain; and a first and a second vertical feed rollrotatably coupled to the first and second portions of the carriage,respectively, and disposed on opposite sides of the sharp chain, whereinthe first and vertical feed rolls are repositionable toward and awayfrom the sharp chain relative to the carriage, and wherein the carriageis configured to vertically reposition the sharp chain and the first andsecond vertical feed rolls in concert to thereby tilt the log while thelog is being conveyed on the sharp chain and engaged by one or both ofthe first and second vertical feed rolls.
 3. (canceled)
 4. The apparatusof claim 2, wherein the first and second vertical feed rolls are a firstpair of vertical feed rolls, the apparatus further comprising a secondpair of vertical feed rolls rotatably coupled to the carriage anddisposed on opposite sides of the sharp chain, wherein the vertical feedrolls of the second pair are fixed in position relative to thecorresponding portions of the carriage.
 5. The apparatus of claim 4,further comprising a third pair of vertical feed rolls rotatably coupledto the carriage and disposed on opposite sides of the sharp chain,wherein the feed rolls of the third pair are repositionable relative tothe corresponding portions of the carriage independently of the firstpair of vertical feed rolls.
 6. The apparatus of claim 5, wherein thethird pair of vertical feed rolls includes a third vertical feed rollcoupled to the first portion of the carriage and a fourth vertical feedroll coupled to the second portion of the carriage, and the first,second, third, and fourth vertical feed rolls are independentlyrepositionable relative to the carriage.
 7. The apparatus of claim 2,further comprising: a first actuator connected to the first portion ofthe carriage and the first vertical feed roll, the first actuatorselectively operable to reposition the first vertical feed roll relativeto said first portion; and a second actuator connected to the secondportion of the carriage and the second vertical feed roll, the secondactuator selectively operable to reposition the second vertical feedroll relative to said second portion.
 8. The apparatus of claim 2,wherein the first and second portions of the carriage are coupled with arail guide system configured to facilitate lateral repositioning of thefirst and second portions.
 9. The apparatus of claim 2, furthercomprising a cylinder coupled with an outfeed end of the sharp chain andthe first and second vertical feed rolls, wherein the cylinder isactuable to vertically reposition the outfeed end of the sharp chain tothereby tilt the log.
 10. The apparatus of claim 2, further comprising afirst cutting device positioned along the sharp chain upstream of thefirst and second vertical feed rolls, wherein the first cutting deviceis operable to cut a flat face along the log and the first vertical feedroll is operable to engage the flat face.
 11. The apparatus of claim 2,further including one or more overhead press roll assemblies operativelycoupled with the conveyor.
 12. The apparatus of claim 11, furtherincluding a second cutting device positioned downstream of the sharpchain and configured to produce a second flat face along the log, thesecond flat face being transverse to the first flat face.
 13. Theapparatus of claim 2, further comprising a scanner system operativelycoupled with the carriage, the scanner system configured to generate oneor more commands to reposition the sharp chain or the vertical feedrolls based at least on a scan of the log.
 14. The apparatus of claim13, further comprising a positioning system upstream of the first andsecond vertical feed rolls and operatively coupled with the scannersystem, wherein the positioning system includes one or more of aconveyor, additional vertical feed rolls, or a log turner, wherein thescanner system is configured to generate one or more commands to causethe positioning device to skew, slew, tilt, and/or rotate the log to adesired position for placement onto the sharp chain.
 15. The apparatusof claim 14, wherein the scanner system is further configured todetermine a difference between the desired position and an actualposition of the log and to generate one or more commands to adjust aposition of the sharp chain, the vertical feed rolls, the carriage, or adownstream cutting device to offset said difference.
 16. The apparatusof claim 13, further including additional vertical feed rolls disposedalong the sharp chain upstream of the first and second vertical feedrolls.
 17. The apparatus of claim 16, wherein the scanner system isconfigured to determine a difference between an actual horizontalposition of the log and a predicted horizontal position of the log, andto generate one or more commands to adjust a position of one or more ofthe vertical feed rolls to offset said difference.
 18. The apparatus ofclaim 13, further comprising a cutting device positioned along orproximal to a downstream end of the sharp chain, wherein the scannersystem is further configured to reposition the cutting device based atleast on the scan of the log.
 19. The apparatus of claim 2, wherein thefirst and second vertical feed rolls are a first pair of vertical feedrolls, the apparatus further including at least one additional pair ofvertical feed rolls disposed along the conveyor on opposite sides of thesharp chain upstream of the first pair of vertical feed rolls.
 20. Theapparatus of claim 19, wherein the vertical feed rolls of at least oneof the pairs are laterally repositionable toward and away from the sharpchain independently of one another.
 21. The apparatus of claim 19,wherein at least one of the pairs of vertical feed rolls is laterallyrepositionable independently of another of the pairs of vertical feedrolls.